Operator’s Manual - Atlingatling.webbo.nu/wp-content/uploads/2015/05/operators-manual-AXE … · rest and on the rollers no unmachined surface should be used. 4.1 Clamping force

Rev-03

Operator’s Manual www.atling.se

Operator’s manual www.atling.com

Self-Centering Steady Rests Hydraulic and pneumatic version

AXE / ASE- series

Before using the machine read and fully understand the contents of this manual

Operator’s Manual Steady Rest

2

ATLINGS THE STEADY REST COMPANY

www.atling.se

Deklaration om överensstämmelse / Declaration of Conformity

Atlings Maskinfabrik AB förklarar härmed

att nedanstående utrustning uppfyller alla

relevanta bestämmelser i 2006/42/EG EG-

direktiv och de nationella lagar och

förordningar där dessa direktiv är

införlivade.

Atlings Maskinfabrik AB hereby certify

that device mentioned below confirms

in all respects to the requirements of

2006/42/EC EC-directive and the

national laws there this directive is

incorporate.

Självcentrerade stöddockor L../AX.. i

pneumatik- eller hydraulikutförande avsedd

att användas inmonterad i annan maskin.

Stöddockan får inte tas i bruk förrän den

maskin eller anläggning som den skall ingå i

överensstämmer med kraven i EG´s

maskindirektiv

Self centering steady rests L../AX.. of

pneumatic or hydraulic design

incorporated into another machinery.

The Steady Rest must not be put into

service until the specific machinery or

construction which it is part of conform

to the specifications in EC´s directive.

Component: Steady Rest

Application: Installation in machine

Type: AXE / ASE / Special

Serial No: ________________________

________________________________________________________________________

Signature of responsible person

Om utrustningen modifierats utan

föregående godkännande från undertecknad

är denna deklaration ogiltig.

If the devices modify without approval

from undersigned this declaration is

irregular.

Tillverkare / Manufacturer

Atlings Maskinfabrik AB

Box 21

816 25 Ockelbo


3

Steady Rests AXE / ASE-Series Dear Customer

Thank you for selecting a product from Atlings Maskinfabrik AB. Our products are

recognized by high quality and accuracy. Active cooperation with our agencies gives us a

high level of service, which will fulfil Your expectations.

How to use and maintenance the Atling Steady Rest, we recommend you to read and fully

understand the contents of this book. This, for you as a customer, to take full advantage of all

built in features of the Steady Rest.

Exploded diagrams are shown to help you understand how the steady is built. They are also

suitable to use in maintenance and service activities.

Do not hesitate to contact Atling or your nearest supplier if there are any questions. We

appreciate any suggestions that will improve our product.

Atlings Maskinfabrik AB

THE STEADY REST COMPANY

Atlings Maskinfabrik AB Hamrångevägen 23 816 31 Ockelbo Sweden Tel + 4629755700 Fax + 4629741600 [email protected] www.atling.com

mailto:[email protected]

http://www.atling.com/


4

ATLINGS THE STEADY REST COMPANY ..................................................................... 2

www.atling.se ..................................................................................................................... 2

1 Safety Instructions ................................................................................................................ 5

2 Principal components and version designations ................................................................ 6

3 General .................................................................................................................................. 7 3.1 Cylinder ........................................................................................................................... 7

3.2 Wipers ............................................................................................................................. 7 3.3 Stroke Control ................................................................................................................. 7 3.4 Coolant flush ................................................................................................................... 7 3.5 Accessories ...................................................................................................................... 7 Steady rest support bracket .................................................................................................... 8

4 Operation conditions ............................................................................................................ 9 4.1 Clamping force and working pressure ............................................................................ 9

4.2 Travelling steady rest ...................................................................................................... 9 4.3 Air barrier or drainage ..................................................................................................... 9 4.4 Lubrication ...................................................................................................................... 9 4.5 Recommended lubricant ................................................................................................ 10

5 Installation .......................................................................................................................... 11 5.1 Mounting the steady rest to the support bracket ........................................................... 11

5.2 Align the steady rest ...................................................................................................... 12 5.3 Coolant flush through levers ......................................................................................... 12 5.4 Installation of proximity switches .................................................................................. 13

5.5 Installation of swing away system ................................................................................. 14

6 Maintenance ........................................................................................................................ 15 6.1 Manual lubrication ........................................................................................................ 15 6.2 Central lubrication ......................................................................................................... 15

6.3 Remaining points of maintenance ................................................................................. 15 6.4 Exchange of rollers and wipers at Middle Piece ........................................................... 16 6.5 Exchange of rollers and wipers at Lever ....................................................................... 17

6.6 Removal of cylinder ....................................................................................................... 18

7 Spare parts .......................................................................................................................... 19 7.1 Exploded view 1 ............................................................................................................ 19 7.2 Exploded view cylinder ................................................................................................. 20 7.3 Article numbers for spare part kits ................................................................................. 21

8 Notes ..................................................................................................................................... 23


5

1 Safety Instructions

Wrong installation and/or careless or wrong use can result in serious damages

and even dangerous to life. All personnel operating or coming in contact with

the steady rest, shall read and fully understand the content of this manual.

Atling or nearest supplier shall be contacted if there is any uncertainty.

Atling steady rests are equipped with safety valves which will prevent the steady rest

from losing its clamping force if the supplied pressure suddenly drops. Lost supply

pressure can cause workpiece to come loose and damage personnel and machine.

Once a year check the safety valve for correct operation.

Never exceed recommended maximum pressure.

The fastening between steady rest and support bracket should be checked at least once

a week. Vibrations can cause the fastening bolts to come loose.

Observe the risk of jamming between the levers.

Hands or other parts of the body shall not be in the near of the steady rest or

workpiece when operated.

Using the travelling steady rest, workpiece must not have any sharp shoulders or

recesses. Safety valve must also be disconnected (see Figure 1 position 8).

Part of workpiece where steady rest clamps must be aligned to centre line between

chuck and spindle.

System pressure shall be checked against weight of workpiece, machining depth

and cutting speed.

Always be careful when working with system under pressure.

Do not clamp on unmachined faces. That can cause damage to the steady rest.

Machining result will never have better accuracy than the surface the steady rest clamp

on.

Use of too high pressure will cause the guide seat to wear out quickly and also reduce

the lifetime considerably.


6

Figure 1. Steady rest with rear mounted cylinder – Axe / ASE-series

2 Principal components and version designations

1. Rollers

2. Levers

3. Thread for eye bolt

4. Coolant connection

5. Air barrier or drainage

6. Connection for opening of cylinder

7. Connection for closing of cylinder

8. Safety valve

9. Stroke control pin

10. Connection for proximity switches

11. Lubricant connection

12. Metering valves

13. Coolant curtain

14. Cylinder

15. Middle piece


7

Figure 2. Self adjusting wipers. Manually adjustable wipers

3 General Atling steady rests are normally used on lathes and grinding machines, manually or automatic

operated machines with flat or slanted beds. The steady rest can also be used in special

applications as to handle long hexagon bars and as grip finger in a robot.

3.1 Cylinder Atling steady rests are pneumatic or hydraulic controlled. The hydraulic or pneumatic

cylinder activates the piston rod and levers to stabilize the workpiece. By adjusting the

pressure the amount of clamping force can be controlled. The maximum allowed working

pressure is specified for each steady rest.

3.2 Wipers Wipers remove dirt from the rollers. The condition of the wipers shall regular be checked and

exchanged if needed. Levers and piston rod are sealed against the housing to prevent dirt and

chips to enter.

3.3 Stroke Control With proximity switches mounted on the cylinder the position of the piston can automatically

be verified. The positions are adjustable, on how to install and adjust them see section 5.4. To

verify only one position only one proximity switch need to be installed.

3.4 Coolant flush The steady rest can be connected to the machine coolant system. By doing this a curtain of

coolant coming out of the levers will prevent chips from getting between the rollers and the

workpiece.

3.5 Accessories There are accessories that can be delivered as non standard, such accessories are:

Workpiece wipers

There are two different designs of workpiece wipers that removes dirt and chips (see Figure

2). Both types are connected to the arms by two screws.


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Figure 3. Support bracket for slant bed machine. Figure 4. Support bracket for flat bed machine.

Steady rest support bracket

The support bracket must be on separate order and will be adapted to the machine fastenings

and the steady rest.

For optimal use of the steady rest the support must be of rigid construction.

In principle, the support construction depends on:

The design of the machine bed

Centre line of the spindle

The location of the centre in relation to the machine bed

The space available to mount the steady

Extra care must be taken when machining and mounting the support to secure that the steady

rest will be exactly perpendicular to the machine bed.

Some examples of brackets with the steady rest mounted:


9

4 Operation conditions The self-centering steady rest demands a turned or grinded workpiece surface which is

aligned to the centre line of the machine. Three rollers (see Figure 1) spaced at approx. 120

degrees centralize the workpiece by controlled cam levers. This gives an accurate centering

and support to the workpiece within the whole clamping range. To avoid damage to the steady

rest and on the rollers no unmachined surface should be used.

4.1 Clamping force and working pressure If maximal recommended clamping force is in use, the rollers life will considerably be

reduced. Extreme high clamping force will in general not lead to a better machining result but

instead roll the rollers into the workpiece. Working pressure to the steady rest depends on

clamping force needed. Parameters controlling this are: depth of cut, speed, feed and

quality of the workpiece.

Note: Machining result will never have better accuracy than the surface the steady rest

clamps on.

4.2 Travelling steady rest When machining long workpieces the steady rest must follow the cutting tool.

When using travelling steady rests the design of the rollers shall be discussed with the

supplier. Travelling steady rests need outwards cambered rollers.

4.3 Air barrier or drainage Additional pressure of about 0,5 bar shall be supplied to the housing to avoid dirt and chips to

enter into the housing. To be connected to the air/drainage connection (see Figure 1 position

5). The use of this feature is very important as it extends the lifetime of the steady rest parts

considerably.

4.4 Lubrication Atling steady rests can be prepared for both automatic oil lubrication and manual grease

lubrication. If the steady rest is prepared for grease lubrication it comes with a lube nipple

connected to the central lube point and there is a –G in the model name e.g. AX6-G. The

steady rest prepared for oil lubrication is equipped with metering valves and one central

lubrication connection, G1/8”.

.

All versions are prepared for central lubrication when delivered.

Atling recommend oil with EP-addition, DIN 51502. Before using the steady rest, lubricate

with the central lubrication system of the machine until oil shows up at the rollers.


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Following is valid at central oil lubrication:

Four (three in AX1E) metering valves are integrated in the housing and connected to a

main line to the hydraulic unit of the machine.

The volume of metering valves range from 0,03 ccm to 0,06 ccm at each lubrication

impulse.

Working pressure of the metering valves shall be 12 – 45 bar.

Relief pressure max. 3 bar.

Lubrication impulses from the machine shall be in intervals of 3 – 5 minutes.

When the machine has not been in use for some time, repeated lubrication impulses

must be given before operation start.

4.5 Recommended lubricant Table will show grease and oil recommended by Atling.

Type of load Grease

Normal DIN 51825-1 to 3

High KP-grease as per DIN 51502

Lubrication oil

All types DIN 51502 with EP-addition


11

Figure 5. The important details when mounting the steady rest to the support.

5 Installation Extreme precision must be taken at installation of the steady rest. Bad

installation will cause damage to the steady rest may cause it not to function

satisfying. It is important to carefully follow the instructions of installation.

Atling or nearest supplier shall be contacted if there is any uncertainty.

5.1 Mounting the steady rest to the support bracket The steady rest mounts on the support bracket with four fastening bolts.

Note: do not tighten the screws before the steady rest has been adjusted by gauge dials

(Table 2).

Mount in following order as per Figure 5. The numbers in the picture corresponds to the order

of mounting.

Mount an eye bolt in the threaded hole (no 1) at side of the housing and lift it.

Mount the four bolts (no 2) that fasten the steady rest to the support.

Note: do not tighten the screws hard but let the steady rest press only slightly on the

support.

Apply hydraulic or pneumatic to the cylinder connection (no 3) for opening and

connection (no 4) for closing, both threads G3/8”. Note: do not use higher pressure

than workpiece can take, and do not exceed recommended maximum pressure (see

Figure 8).

Before the fastening bolts are tightened, follow the instruction how to align the steady

rest (next page).

When connecting to the hydraulic system of the machine, information must be

collected from the machine supplier to ashore correct installation.


12

Figure 6. It is important that dial gauges are positioned 90 degrees apart .

5.2 Align the steady rest

Note: If working pressure is changed a new alignment must be done.

Clamp an accurate machined shaft between two centres. With a dial gauge check the

run out of truth for the shaft. Exchange the shaft if the run out of truth is abnormal

great.

Mount two dial gauges to the shaft as per Figure 6.

Activate the cylinder with selected working pressure (see Figure 8), make the steady

rest open and close so that the rollers clamp the shaft. Note: the steady rest must not

be tightened to the bracket at this time.

Check the dial gauges if the centre of rotation has moved in any direction. Depending

on how accurate result is needed, the movement should be as small as possible.

Tighten the fastening bolts using torque as per Table 2.

Open and close the steady rest once more. Check the dial gauges.

5.3 Coolant flush through levers To all AX-series models it is possible to connect the steady rest to the coolant system to

efficient remove chips by the rollers and create a curtain the prevent them for getting in

between rollers and the workpiece which can cause damage to both. The connection for the

coolant is in the top cover of the steady (see Figure 1) and is a G1/4” thread (G1/8” AX1E).

Recommended pressure for the coolant: 10-20 bar. Maximum pressure: 70 bar.

Dial gauge 1

Dial gauge 2

Machined shaft


13

5.4 Installation of proximity switches All steady rest in the Atling AXE / ASE-series comes prepared for use of two inductive

proximity switches. On the cylinder housing there are two M12x1 threaded holes

(AX1E=M8x1) (see Figure 1 position 10). It is possible to use both or just one, depending on

how many positions needs to be detected. In case of use of only one, either the rear or the

front slot can be used. The measured positions are defined by the nuts positions on the stroke

control pin (see Figure 1). Compared to our previous stroke control system this one is

completely sealed which extends the lifetime of the proximity switches.

How to adjust the measure points:

Remove the plug on the back of the cylinder. Unscrew the outer nut on the stroke control pin

by using the wrench that came with the steady rest. Then adjust the inner nut to its wanted

position and then put back the first nut and adjust it as desired. Finally put the plug back in.

The stroke control pin can also be removed. This can be done when the steady rest is in its

most open position. At this point remove the small plug on the top (Figure 7 position 5) of the

steady rest and unscrew the top screw underneath (Figure 7 position 6). Then remove the plug

on the back of the cylinder. It is now possible to unscrew the stroke control pin and remove it

from its position.

Figur 7. Exploded view of the stroke control system.

1 – Special wrench, 2 – Plug G3/8”, 3 – Nut M6 (2 pcs), 4 – Stroke control pin M6, 5 – Plug G1/8”


14

5.5 Installation of swing away system The Atling AX-series provides the end-user the possibility to install a swing away system

retrospectively. This is done by changing the track plate (see position 3-1/3-2 in Exploded

view 1). This will make the lever open an extra amount which gives the user more space when

changing work pieces. These track plates can be installed by the Atling factory or by the end

user. To change plates the steady rest cover lid need to be removed, once again see the

Exploded view 1. The plates are symmetrical which makes them suitable for both upper and

lower lever.

Table 3. Shows approximate relationship between hydraulic

pressure and gripping force on different models of steady rests.

Table 2. Shows torque and max. pressure

relating to different sizes of the steady rest.


15

6 Maintenance

Care shall be taken when maintaining the steady rest. To avoid injuries the

hydraulic and peumatic pressure shall be switched off if not needed for

maintaining the steady rest. Be sure there is no pressure on the cylinder when

exchanging the safety valve. Atling recommend extensive maintenance and repair

to be performed by the supplier, or by other qualified service personnel.

6.1 Manual lubrication Maintenance includes, among other things, lubrication of rollers and roller taps at both levers

and piston rod. They are lubricated from the grease nipple (see Figure 1).

Note: No metering valves shall be used in manual lubrication.

Use grease gun with recommended bearing grease DIN 51825-1 to 3 at normal load.

Lubricate the steady rest via the grease nipple in intervals of 3 – 6 hours at continuous

running depending on load.

When lubricating the old grease shall be pushed out by the new grease.

6.2 Central lubrication

Check daily that lubrication oil comes out at all three rollers and at the piston rod.

Recommended lubrication interval is 3 – 5 minutes.

6.3 Remaining points of maintenance

1 to 3 times per year, depending on utility, check the torque of fastening bolts for

steady rest to support and support to machine.

Once a week, check the cylinder for leakage.

Check the rollers by rotating them to detect any play.

Exchange when needed (see next page).

At least once a year the safety valve shall be checked. This is done by switching the

steady rest On and then supply pressure Off. If the steady rest looses its pressure then

there is something wrong with the valve, and must immediately be exchanged.

Perform an annual inspection (dismount the cover, exchange any damaged parts, clean

all parts and lubricate).

Daily check the status of the both wipers and seals.

Exchange wipers when needed (see next page).


16

Figure 8. Shows dismounting sketch for middle piece roller.

6.4 Exchange of rollers and wipers at Middle Piece

Dismounting is done in order as per Figure 8.

Unfasten screws (no 33-1) which holds the wiper

Dismount the wiper (no 31) by pulling it straight out

Unfasten screw (no 18) who locks the roller tap in the lever

Carefully knock away the tap (no 8) with a brass drift or use a puller

Remove the roller (no 10)

Mount in reverse order with new roller and a possible new wiper. Check so the roller can be

rotated after the wiper have been mounted, otherwise adjust the wiper a little.


17

Figure 9. Shows dismounting sketch for lever

6.5 Exchange of rollers and wipers at Lever

Dismounting is done in order as per Figure 9.

Unfasten screws (no 33 and 22) which holds the wiper

Dismount the wiper (no 32) by pulling it straight out

Unfasten screw (no 18) who locks the roller tap in the lever

Carefully knock away the tap (no 8) with a brass drift or use a puller

Remove the roller (no 10)

Mount in reverse order with new roller and a possible new wiper. Check so the roller can be

rotated after the wiper have been mounted, otherwise adjust the wiper a little.


18

Figur 9. Dismounted cylinder

6.6 Removal of cylinder To change seals and wipers for the piston and cylinder the back part needs to be removed. Be

sure to have the steady rest in its most open position and to empty the cylinder on hydraulic

fluids. Then dismount the steady rest as following:

Start with removing the plug in the top cover (position 1 Figure 9), then remove the pin

beneath (position 2 Figure 9). Unscrew the four screws in position 3. Now the pull back the

cylinder housing.


19

7 Spare parts 7.1 Exploded view 1


20

7.2 Exploded view cylinder


21

7.3 Article numbers for spare part kits

Steady rest

Seal kit House

Seal kit Cylinder Wipers kit Rollers kit

Shafts kit

AX1E A5550101 A5550102 A5550103 A5550104 A5550105

AX2E A5550201 A5550202 A5550203 A5550204 A5550205

AX3E A5550301 A5550302 A5550303 A5550304 A5550305

AX4E A5550401 A5550402 A5550403 A5550404 A5550405

AX4I A5550401 A55504i2 A5550403 A5550404 A5550405

AX5E A5550501 A5550502 A5550503 A5550504 A5550505

AX5I A5550501 A55505i2 A5550503 A5550504 A5550505

AX6E A5550601 A5550602 A5550603 A5550604 A5550605

AX6I A5550601 A55506i2 A5550603 A5550604 A5550605

AX7E A5550701 A5550702 A5550703 A5550704 A5550705

AX7I A5550701 A55507i2 A5550703 A5550704 A5550705

AX8E A5550801 A5550802 A5550803 A5550804 A5550805

AX8I A5550801 A55508i2 A5550803 A5550804 A5550805

AX8.5E A5550901 A5550902 A5550903 A5550904 A5550905

AX8.5I A5550901 A55509i2 A5550903 A5550904 A5550905

AX8.7E A5550901 A5550902 A5550903 A5550904 A5550905

AX8.7I A5550901 A55509i2 A5550903 A5550904 A5550905

AX9E A5550901 A5550902 A5550903 A5550904 A5550905

AX9I A5550901 A55509i2 A5550903 A5550904 A5550905

AX10E A5551001 A5551002 A5551003 A5551004 A5551005

AX10I A5551001 A55510i2 A5551003 A5551004 A5551005

AX11E A5551101 A5551102 A5551103 A5551104 A5551105

AX11I A5551101 A55511i2 A5551103 A5551104 A5551105


22


23

8 Notes

Documents

Operator’s Manual - Atlingatling.webbo.nu/wp-content/uploads/2015/05/operators-manual-AXE … · rest and on the rollers no unmachined surface should be used. 4.1 Clamping force